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Intruder VZ800
User Manuals: SUZUKI Intruder VZ800 Motorcycle
Manuals and User Guides for SUZUKI Intruder VZ800 Motorcycle. We have
2
SUZUKI Intruder VZ800 Motorcycle manuals available for free PDF download: Service Manual, Manual
Suzuki Intruder VZ800 Service Manual (454 pages)
Brand:
Suzuki
| Category:
Motorcycle
| Size: 23.13 MB
Table of Contents
General Information 1
8
General Information
2
Periodic Maintenance
2
Electrical System
2
Servicing Information
2
Wiring Diagram
2
How to Use this Manual
3
Abbreviations Used in this Manual
5
Table of Contents
8
General Precautions
9
Suzuki Vz800K5 ('05-Model)
11
Engine Oil
12
Brake Fluid
12
Front Fork Oil
12
Serial Number Location
11
Fuel, Oil and Engine Coolant Recommendation
11
Cylinder Identification
13
Information Labels
14
Specifications
15
Dimensions and Dry Mass
15
Drive Train
15
Chassis
16
Periodic Maintenance Schedule
18
Periodic Maintenance Chart
18
Lubrication Points
19
Maintenance and Tune-Up Procedures
20
Air Cleaner
20
Spark Plug
21
Valve Clearance
23
Fuel Hose
26
Engine Oil Replacement
27
Engine Oil and Oil Filter
27
Engine Idle Speed
29
Throttle Cable Play
30
Throttle Valve Synchronization
31
Evaporative Emisson Control System (for E-33 Only)
31
Pair (Air Supply) System
31
Clutch
32
Cooling System
33
Engine Coolant Level Check/Change
33
Final Gear Oil
35
Brake
35
Tire
39
Steering
39
Tire Tread Depth
39
Front Fork
40
Rear Suspension
40
Exhaust Pipe Bolt
40
Chassis Bolt and Nut
41
Compression Pressure Check
43
Compression Test Procedure
43
Oil Pressure Check
44
Oil Pressure Test Procedure
44
Sds Check
45
Sample
45
Data Sampled from Cold Starting through Warm-Up
45
Data at 3 000 R/Min under no Load
46
Data at the Time of Racing
46
Engine
47
Engine Components Removable with Engine in Place
48
Engine Removal and Installation
49
Engine Removal
49
Engine Installation
54
Engine Disassembly
57
Engine Components Inspection and Servicing
73
Cylinder Head Cover
73
Camshaft
74
Cam Chain Tensioner and Guide
76
Cylinder Head
76
Cylinder
86
Piston
87
Piston Diameter
87
Piston Ring Groove Width
87
Piston Ring Thickness
87
Piston Ring End Gap
88
Conrod/Crankshaft
90
Clutch
99
Generator/Signal Generator/ Starter Clutch
100
Oil Pump
102
Transmission
103
Gearshift Fork
106
Oil Jet
106
Crankcase
107
Engine Reassembly
111
Shaft Drive
133
Secondary Bevel Gears
134
Construction
134
Removal
136
Disassembly
136
Inspection
137
Secondary Gear Shims Adjustment
138
Reassembly
142
Installation
142
Final Bevel Gears
143
Construction
143
Final Gear Case Removal
145
Final Gear Case Disassembly
145
Final Gear Shims Adjustment
149
Final Gear Case Reassembly
153
Final Gear Case Installation
157
Fi System
158
Precautions in Servicing
160
Connector/Coupler
160
Fuse
161
Ecm/Various Sensors
161
Electrical Circuit Inspection Procedure
163
Using the Multi-Circuit Tester
166
Fi System Technical Features
167
Injection Time (Injection Volume)
167
Compensation of Injection Time (Volume)
168
Injection Stop Control
168
Fi System Parts Location
169
Fi System Wiring Diagram
171
Ecm Terminal
172
Self-Diagnosis Function
173
User Mode
173
Dealer Mode
174
Tps Adjustment
176
Fail-Safe Function
177
Fi System Troubleshooting
178
Customer Complaint Analysis
178
Visual Inspection
179
Self-Diagnostic Procedures
180
Self-Diagnosis Reset Procedure
180
Use of Sds Diagnostic Procedures
181
Use of Sds Diagnosis Reset Procedure
182
Show Data When Trouble (Displaing Data at the Time of Dtc)
183
Malfunction Code and Defective Condition
184
C12" (P0335) Ckp Sensor Circuit Malfunction
187
C13" (P1750) or "C17" (P0105) IAP SENSOR CIRCUIT MALFUNCTION
190
C14" (P0120-H/L) Tp Sensor Circuit Malfunction
194
C15" (P0115-H/L) Ect Sensor Circuit Malfunction
199
Ect Sensor Inspection
203
C21" (P0110-H/L) Iat Sensor Circuit Malfunction
204
C23" (P1651-H/L) to Sensor Circuit Malfunction
209
C24" (P0351) or "C25" (P0352) IGNITION SYSTEM MALFUNCTION
212
C28" (P1655) Stv Actuator Circuit Malfunction
213
C29" (P1654-H/L) Stp Sensor Circuit Malfunction
216
C31" (P0705) Gp Switch Circuit Malfunction
221
C32" (P0201) or "C33" (P0202) FUEL INJECTOR CIRCUIT MALFUNCTION
223
C41" (P0230) Fp Relay Circuit Malfunction
225
C42" (P01650) Ig Switch Circuit Malfunction
225
C44" (P0130/P0135) Ho2 Sensor (Ho2S) Circuit Malfunction (for E-02, 19, 24)
226
C49" (P1656) Pair Control Solenoid Valve Circuit Malfunction
230
Iap Sensor Inspection
232
Iap Sensor Removal/Installation
232
Sensors
232
Tp Sensor Inspection
232
Tp Sensor Removal/Installation
232
Ckp Sensor Inspection
233
Ckp Sensor Removal/Installation
233
Stp Sensor Inspection
233
Stp Sensor Removal/Installation
233
Ect Sensor Inspection
234
Ect Sensor Removal/Installation
234
Iat Sensor Inspection
234
Iat Sensor Removal/Installation
234
To Sensor Inspection
234
To Sensor Removal/Installation
234
Ho2 Sensor Inspection (for E-02, 19, 24)
235
Ho2 Sensor Removal/Installation
235
Fuel System and Throtle Body
236
Fuel Delivery System
237
Fuel System
238
Fuel Tank Removal
238
Fuel Tank Installation
238
Fuel Pressure Inspection
239
Fuel Pump Inspection
240
Fuel Discharge Amount Inspection
240
Fuel Pump Relay Inspection
241
Fuel Pump Removal and Disassembly
242
Fuel Mesh Filter Inspection and Cleaning
246
Fuel Pump Reassembly and Installation
246
Throttle Body
247
Construction
247
Air Cleaner Box Removal
248
Air Cleaner Box Installation
248
Throttle Body Removal
248
Throttle Body Disassembly
249
Throttle Body Cleaning
252
Inspection
252
Throttle Body Reassembly
252
Throttle Body Installation
255
Stp Sensor Adjustment
256
Fuel Injector Removal
256
Fuel Injector Inspection
256
Fuel Injector Installation
257
Fast Idle
257
Fast Idle Adjustment
257
Throttle Valve Synchronization
259
Throttle Position Sensor (Tps) Setting
260
Cooling and Lubrication System
261
Engine Coolant
262
Cooling Circuit
263
Cooling Circuit Inspection
263
Radiator and Water Hoses
264
Radiator Removal
264
Radiator Cap Inspection
265
Radiator Inspection and Cleaning
265
Radiator Remounting
265
Water Hose and Reservoir Tank Inspection
266
Cooling Fan
267
Inspection
267
Removal
267
Installation
268
Cooling Fan Thermo-Switch
269
Removal
269
Inspection
269
Installation
269
Engine Coolant Temperature Sensor
270
Removal
270
Inspection
270
Installation
271
Thermostat
272
Removal
272
Inspection
272
Installation
273
Water Pump
274
Removal and Disassembly
274
Inspection
275
Reassembly and Installation
276
Lubrication System
279
Oil Pressure
279
Oil Filter
279
Oil Pressure Regulator
279
Oil Strainer
279
Oil Jet
279
Oil Pump
279
Oil Pressure Switch
279
Engine Lubrication System Chart
280
Chassis
281
Exterior Parts
283
Removal
283
Remounting
284
Front Wheel
285
Construction
285
Removal and Disassembly
287
Inspection
288
Reassembly and Remounting
289
Front Fork
292
Construction
292
Removal and Disassembly
293
Inspection
296
Reassembly and Remounting
297
Handlebar
301
Construction
301
Reassembly and Remounting
302
Removal and Disassembly
302
Steering
304
Construction
304
Removal and Disassembly
305
Inspection and Disassembly
307
Reassembly and Remounting
307
Steering Tension Adjustment
310
Rear Wheel
311
Construction
311
Removal
313
Disassembly
314
Inspection and Disassembly
315
Reassembly and Remounting
316
Rear Suspension
318
Construction
318
Removal
320
Inspection and Disassembly
323
Reassembly
325
Remounting
326
Rear Shock Absorber Disposal
329
Suspension Setting
329
Chassis
330
Front Brake
330
Construction
330
Brake Pad Replacement
332
Brake Caliper Removal and Disassembly
333
Brake Fluid Replacement
333
Brake Caliper Inspection
334
Brake Caliper Reassembly and Remounting
335
Brake Disc Inspection
336
Master Cylinder Removal and Disassembly
337
Master Cylinder Inspection
338
Master Cylinder Reassembly and Remounting
339
Rear Brake
341
Construction
341
Inspection
342
Removal and Disassembly
342
Reassembly and Remounting
343
Rear Brake Rod
344
Reassembly Remounting
345
Inspection
346
Tire and Wheel
346
Tire Removal
346
Valve Inspection
347
Tire Installation
348
Balancer Weight Installation
349
Electrical System
350
Cautions in Servicing
352
Clamp
352
Connector
352
Coupler
352
Fuse
352
Battery
353
Connecting the Battery
353
Semi-Conductor Equipped Part
353
Wiring Procedure
353
Using the Multi-Circuit Tester
354
Location of Electrical Components
355
Charging System
357
Troubleshooting
357
Inspection
358
Starter System and Side-Stand/Ignition Interlock System
361
Troubleshooting
361
Starter Motor Removal and Disassembly
363
Starter Motor Inspection
364
Starter Motor Reassembly
364
Starter Relay Inspection
365
Side Stand/Ignition Interlock System Parts Inspection
366
Electrical
369
Spark Plug
369
Battery
369
Fuse
369
Ignition System
369
Troubleshooting
369
Inspection
371
Description
374
Speedometer and Pilot Lamp Box
374
Speedometer Removal and Disassembly
375
Pilot Lamp Box Removal and Disassembly
377
Inspection
378
Brake Light/Taillight
382
Headlight, Brake Light/Taillight, License Plate Light and Turn Signal Light
382
Lamps
382
Fuel Pump Relay
384
Relays
384
Starter Relay
384
Switches
384
Turn Signal/Side-Stand Relay
384
Battery
386
Initial Charging
386
Specifications
386
Recharging Operation
388
Servicing
388
21 W
382
Servicing Information
389
Troubleshooting
390
Fi System Malfunction Code and Defective Condition
390
Engine
393
Radiator (Cooling System)
398
Chassis
399
Shaft Drive
400
Brakes
400
Electrical
401
Battery
402
Wiring Harness, Cable and Hose Routing
403
Wiring Harness Routing
403
Cable Routing
406
Throttle Body Installation
407
Cooling System Hose Routing
408
Front Brake Routing
409
Speed Sensor Harness Routing
410
Front Turn Signal Installation
410
Front Turn Signal Lead Wire Routing
411
Muffler & Exhaust Pipe Installation
411
Handlebar Balancer
412
Battery Protector
412
Lubrication Points
413
Fuel Tank Installation
414
Rear Combination Lamp Installation
415
Frame Head Cover Cushion Installation
416
Left Side Cover Cushion Installation
416
Rear Fender Cushion Installation
417
Left Side Cover Installation
418
Lid Cushion Instsallation
419
Tail Lamp Installation
420
Pair (Air Supply) System Diagram
421
Pair (Air Supply) System Hose Routing
422
Special Tools
423
Tightening Torque
427
Engine
427
Secondary and Final
428
Fi System and Intake Air System
428
Cooling System
428
Chassis
429
Tightening Torque Chart
430
Service Data
431
High Beam Indicator Light
438
Neutral Indicator Light
438
Speedometer Light
438
Turn Signal Indicator Light
438
Emission Control Information
441
Emission Control Systems
442
Fuel Injection System
442
Exhaust Emission Control System (Pair System)
443
Noise Emission Control System
444
EVAPORATIVE EMISSION CONTROL SYSTEM (Only for E-33)
444
Pair (Air Supply) System Inspection
445
Hoses
445
Pair Reed Valve
445
Pair Control Solenoid Valve
446
Pair (Air Supply) System Hose Routing
447
Heated Oxgen Sensor (Ho2S) Inspection (for E-02, 19, 24)
448
EVAPORATIVE EMISSION CONTROL SYSTEM INSPECTION (Only for E-33)
449
Only for E
449
HOSES (EVAP Hose)
449
Evap Canister
449
EVAP CANISTER HOSE ROUTING (Only for E-33)
450
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SUZUKI Intruder VZ800 Manual (315 pages)
Brand:
SUZUKI
| Category:
Motorcycle
| Size: 29.38 MB
Table of Contents
Group Index
1
Component Parts and Work to be Done
2
Symbol
3
General Information
4
Warning/Caution/Note
5
General Precautions
5
Serial Number Location
7
Fuel
7
Engine Oil
8
Brake Fluid
8
Anti-Freeze/Engine Coolant
8
Liquid Amount of Water/Engine Coolant
8
Break-In Procedures
9
Cylinder Identification
9
Information Labels
10
Specifications
11
Country or Area
13
Periodic Maintenance
14
Lubrication Points
16
Maintenance and Tune up Procedures
17
Air Cleaner
17
Air Cleaner Element Removal
17
Valve Clearance
18
Air Cleaner Element Remounting
18
Spark Plug
21
Engine Oil and Oil Filter
22
Fuel Hose
23
Carburetor
23
Engine Idle RPM
23
Returning Cable Play
23
Carburetor Synchronization
24
Clutch
24
Engine Coolant
24
Drive Chain
25
Checking
25
Drive Chain Adjusting
26
Drive Chain Cleaning and Lubricating
26
Front Brake
27
Brake Fluid Level
27
Brake Pads
27
Air Bleeding the Brake Fluid Circuit
28
Brake Pedal Height and Free Travel
28
Tire Tread Condition
29
Tire Pressure
29
Brake Light Switch
29
Brake Shoe Wear
29
Steering
30
Front Fork
30
Rear Suspension
30
Exhaust Pipe Bolts
30
Chassis Bolts and Nuts
31
Compression Pressure Check
33
Compression Pressure Specification
33
Compression Test Procedure
33
Low Compression Pressure
33
Oil Pressure Check
34
Oil Pressure Test Procedure
34
Low Oil Pressure
34
High Oil Pressure
34
Engine
35
Engine Components Removable with the Engine in Place
36
Engine Center
36
Engine Right Side
36
Engine Left Side
36
Engine Removal
37
Engine Reinstallation
43
Engine Disassembly
46
Engine Components Inspection and Servicing
59
Cylinder Head Cover and Rocker Arm
59
Cylinder Head Cover Distortion
59
Rocker Arm Shaft O.D.
59
Camshaft
61
Camshaft Cam Wear
61
Camshaft Journal Wear
61
Camshaft Journal Oil Clearance
61
Cam Chain Tensioner and Guide
62
Cam Chain Tensioner
62
Camshaft Runout
62
Cylinder Head, Valve and Valve Spring
63
Valve and Valve Spring Disassembly
63
Cylinder Head Distortion
63
Valve Face Wear
63
Valve Stem Runout
64
Valve Head Radial Runout
64
Valve Stem Deflection
64
Valve Stem Wear
64
Valve Guide Servicing
65
Valve Seat Width
66
Valve Seat Servicing
66
Valve Stem End Condition
68
Valve Spring
68
Valve and Valve Spring Reassembly
68
Cylinder Distortion
70
Cylinder Bore
70
Piston Diameter
70
Piston to Cylinder Clearance
71
Piston Ring to Groove Clearance
71
Piston Ring Free End Gap and End Gap
71
Piston Pin and Pin Bore
72
Conrod Small End I.D.
73
Conrod Big End Thrust Clearance
73
Conrod-Crank Pin Bearing Selection
73
Crank Pin Bearing Oil Clearance
74
Bearing Selection Table
74
Conrod I.D. Specification
75
Crank Pin O.D. Specification
75
Conrod-Crank Pin Bearing Assembly
76
Crankcase-Crankshaft Bearing Selection
76
Crankshaft Thrust Clearance
78
Clutch Drive and Driven Plates
79
Clutch Spring Free Length
79
Clutch Bearing
79
Clutch Release Rack and Pinion
80
Generator Stator and Signal Generator Stator Inspection
80
Generator Stator Servicing
80
Starter Clutch Inspection
80
Oil Pump
81
Starter Driven Gear Bearing Inspection
81
Starter Clutch Servicing
81
Transmission Disassembly
82
Transmission Gears and Related Parts
84
Gear-Shifting Fork Clearance
85
Oil Jey and Nozzle
85
Engine Reassembly
86
Location of Cylinder Head Bolt
107
Location of Cylinder Head Cover Bolt
107
Fuel and Lubrication System
109
Fuel System
110
Fuel Pump Description
111
Starting Engine
111
After Start
111
Fuel Pump Removal
112
Fuel Pump Inspection
112
Fuel Tank and Fuel Valve
113
Fuel Valve Mechanism
113
Fuel Tank Removal
113
Fuel Filter Removal
114
Carburetor Construction
115
Rear Carburetor
116
I.D. No. Location
118
Diaphragm and Piston Operation
119
Slow System
120
Transient Enrichment System
120
Main System
121
Starter System
122
Float System
122
Carburetor Cleaning
130
Needle Valve Inspection
130
Fuel Level Inspection
131
Float Height Adjustment
132
Throttle Position Switch Inspection
133
Reassembly and Remounting
133
Throttle Valve
133
Coasting Valve
133
Pilot Air Jet
134
Needle Jet
134
Pilot Jet, Main Jet and Valve Seat
134
Float Chamber
135
Piston Valve and Carburetor Top Cap
135
Starter Plunger
135
Throttle Cables
136
Carburetor Clamp
136
Pulling Cables
136
Returning Cable
136
Balance of Carburetors
137
Calibrating each Gauge
138
Lubrication System
139
Engine Lubrication System Chart
140
Cooling System
141
Cooling System Description
142
Cooling System Construction
143
Radiator and Water Hoses Removal
146
Cooling System Inspection
147
Radiator Cap Inspection
147
Radiator Inspection and Cleaning
148
Water Hoses
148
Radiator Mounting Bolt and Clamp
148
Cooling Fan Removal
149
Cooling Fan Inspection
150
Cooling Fan Installation
150
Cooling Fan Thermo-Switch Removal
150
Cooling Fan Thermo-Switch Inspection
151
Cooling Fan Thermo-Switch Installation
151
Engine Coolant Temperature Switch Removal
152
Engine Coolant Temperature Switch Inspection
152
Engine Coolant Temperature Switch Installation
152
Water Pump Removal
153
Water Pump Bearing
155
Mechanical Seal
155
Chassis
159
Exterior Parts
160
Frame Cover
160
Steering Head Cover
160
Seat
160
Front Wheel Removal
161
Front Wheel Inspection and Disassembly
162
Speedometer Gearbox
162
Wheel Bearings
162
Front Axle
163
Brake Disc
164
Tire and Wheel
165
Tire Removal
165
Wheel Inspection
167
Tire Inspection
167
Valve Inspection
167
Valve Installation
168
Tire Installation
168
Brake Pad Replacement
171
Brake Fluid Replacement
171
Caliper Removal and Disassembly
172
Caliper Inspection
173
Caliper Reassembly and Remounting
173
Brake Disc Inspection
174
Master Cylinder Removal and Disassembly
174
Master Cylinder Inspection
175
Master Cylinder Reassembly and Remounting
176
Damper/Inner Tube
180
Outer Tube
180
Oil Seal
180
Fork Oil
181
Front Fork Remounting
184
Steering Inspection and Disassembly
187
Rear Wheel and Brake
190
Rear Axle
193
Wheel Damper
193
Sprocket
193
Brake Shoe
194
Brake Drum
194
Rear Sprocket Mounting Drum Bearing
195
Rear Brake Pedal
196
Rear Suspension and Swingarm
198
Swingarm Pivor Bearings
200
Shock Absorber
200
Swingarm Pivot Shaft
200
Chain Buffer
201
Swingarm Bearing
201
Rear Swingarm Pivot Nut
201
Final Inspection and Adjustment
202
Rear Axle and Torque Link Nut
202
Suspension Setting
202
Electrical System
203
Cautions in Servicing
204
Connector
204
Coupler
204
Clamp
204
Connecting Battery
205
Using Multi Circuit Tester
205
Location of Electrical Components
206
Charging System Description
208
Function of Regulator
208
Troubleshooting
210
Battery Runs down Quickly
210
Battery Leak Current Inspection
211
Charging Output Inspection
211
Generator Coil Continuity Inspection
212
Generator No-Load Performance Inspection
212
Regulator/Rectifier Inspection
212
Starter System Description
213
Side-Stand/Ignition Interlock System Description
213
Starter Motor will Not Run
215
Starter Motor Removal and Disassembly
216
Starter Motor Inspection
216
Carbon Brush
216
Starter Motor Reassembly
217
Commutator
217
Armature Coil Inspection
217
Oil Seal Inspection
217
Starter Relay Inspection
218
Starter Control Relay Inspection
219
Side-Stand/Ignition Interlock System Part Inspection
220
Diode
220
Neutral Switch
220
Side-Stand Switch
221
Side-Stand/Ignition Interlock Relay
221
Ignition System Description
222
No Spark or Poor Spark
223
Ignition Coil Primary Peak Voltage
224
Ignition Coil Resistance
225
Signal Generator
226
Signal Generator Resistance
227
Speedometer and Instrument Panel Removal and Disassembly
228
Lamps
230
Headlight
230
Bulb Replacement
230
Tail/Brake Light
231
Turn Signal Light
232
Starter Relay
232
Turn Signal Relay
232
Switches
233
Battery Specifications
234
Initial Charging
234
Filling Electrolyte
234
Recharging Operation
236
Servicing Information
237
Wiring Diagram
246
Wire Harness Routing
247
Cable Routing
250
Fuel System Hose Routing
251
Cooling System Hose Routing
253
Pair (Air Supply) System Hose Routing
254
Front Brake Hose Routing
255
Special Tools
256
Tightening Torque
258
Tightening Torque Chart
260
Service Data
261
Emission Control Information
269
Emission Control Carburetor Components
270
Evaporative Emission Control System
271
Canister Hose Routing
272
Evaporative Emission Control System Inspection
272
Pair System Diagram
273
Reed Valve of Pair Control Valve
275
Pair Control Valve
275
Vz800W
276
Vz800X/Y/K1/K2
294
Engine Idle RPM (Idle Adjustment)
306
Exhaust Pipe and Muffler
306
Engine Side Box Set-UP
307
Evaporative Emission Control System Hose Routing
309
Carburetor Surge Control Valve
312
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